1595.1595.01 | ra 4 i ; 4 I il Re Rove eg ek et ero ner) pede eae)HEATH COMPANY PHONE DIRECTORY ‘The folowing telephone numbors aro roc! ines tothe departments iste: Kit orders and delivery information .. coos (616) 989.9601 Credt (616) 962-9561 placement Paris - : (16) 982-3571 Technical Assistance: : FRG, Audio, and Eleronlo Organs (616) 982-6310 Amateur Racio z (616) 982.0296 “Test Equipment, Svobe Lights, Caleuator, (Cocks, Weather Instruments ooo (616) 9823915 Television (16) 982-5907 ‘Automotive, Marine. Appliances, Secutty, General Products (616) 982-9496 Qa YOUR HEATHKIT 90-DAY FULL WARRANTY = oe = ‘uy pars which ape detective ether Inmates or workman. You can obtain pats diet rm Heat Cnn by rng usr tlphnlng us et 616) 9623871. And wel pay shipping charges to ge thoes pats yo anvwhee i the i] tnd used in accrdenct with mor printed insevtions il mevt published specications a etectve part or error indesign has uae sor Heth pode to malfunction daring the waranty prio, tnough 92 {aul youre we wil evict reo pon dlisery your expen othe Heath facory, Banton Harbor, Mlchiga, ore ay oathki flocconic Centr (unis of Sehlumberger Products Corporation o though any of ou authorized versus die feos oF ee ee ee 7 ‘You wil wciv re conslation om any problar you might encounter inthe nop us ine or give ura call Soy ve cannot accept elle call smbly ous of your Heath produc. ut ‘Our warranty, both expressed and imple, does not cover damage cast bus of corrosive older, defectives incoret ‘emblems, fe cutomermede modlfcetions aod erste of Cod. nor dogs include laurent fr Cure? {seembly cr soup tine The waranty covers only Heth prodocts and is net extended lo nenHelh allied exipment oF ‘components used in conjunction wih ou peoducts ora of aur padi for purpore tbe hen ax eden, ee ‘a ea ate died with vor — wary o ein or nr pod wn ct ou Dich of tomer Services Heath Company Benton Harbor Michigan, 40022 ell mabe cra your probleme cai uted, ‘meal stain HEATH COMPANY BENTON HARBOR, Ml 48022 = = San STS SE NESS Prices and specications subject to change without notice. inAssembly and Operation of the GS nearsnir LINEAR AMPLIFIER MODEL SB-230 HEATH COMPANY BENTON HARBOR, MICHIGAN 49022Page 2 a= == TABLE OF CONTENTS INTRODUCTION . +--+ eee eee See ASSEMBLYNOTES ........... be CIRCUIT BOARDS Parts List... ee eee ee bee? Step-by-Step Assembly 2.2... 0 ee ee oe 9 CHASSIS Parts List ©. 2 ee ee eee 2 13 STEP-BY-STEPASSEMBLY ©... 6... ee ee - 29 RE Chassis eee - ++ 30 RF Enclosure. . . rn - 46 Power Supply Chassis... . Sees 2. 48 Assembled Chassis... 2. bbe eee 58 TESTS ANDFINALASSEMBLY ..............000. 87 INSTALLATION 2... 02.02 ee ces 89 OPERATION Control Functions... 2... Fee eee 93 Reading the Meter ©... 2... ee : er) Driving Power os cee eee ses. 96 TuneUp 2. eee bee INCASE OF DIFFICULTY ©... 2... ee eee 101 Troubleshooting... . : cea cee 103 SPECIFICATION cee 105 CIRCUIT DESCRIPTION... . .- - 107 CHASSIS PHOTOGRAPHS. cee 109 CIRCUIT BOARD X-RAY VIEWS. . cee 1B SCHEMATIC . . . (fold-out from page) : : oe 3 WARRANTY .... sone Inside front cover CUSTOMER SERVICE .. 2... Inside rear coverINTRODUCTION ‘The Heathkit Model SB-230 Linear Amplifier is a completely self-contained, grounded-grid, table top amplifier for use on the 80, 40, 20, 15 and 10 meter amateur bands. Because it uses a type 8873 tube, which is conduction cooled by a large heat sink, fan noise is eliminated and it is, completely quiet in operation. The Amplifier is rated at a power input of 1200 watts peak envelope power for voice operation on SSB, at 1000 watts for CW, or at 400 watts for RTTY or SSTV. ‘The power transformer has @ dual primary winding and can be operated from either 120 or 240 VAC, 50/60 Hertz clectric supply lines, Operation from a 240 volt line is recommended, but not required. The Amplifier is designed for use with exciters which deliver 100 watts output. It can be used with lower driving power, but its output will be less. If it is overdriven, the Amplifier develops ALC voltage to reduce the gain of the exciter. An “exciter only” switch is provided so the Amplifier, after warm-up, can be instantaneously switched into or out of use. Protective devices are: a circuit breaker in the power transformer primary, a time delay to insure adequate warm-up time for the tube, a thermal breaker to cut off the tube should the Amplifier be overheated, and a fuse to protect against excessive plate drive. Convenient visual indicators are included on the panel to show when the ‘Amplifier is ready to operate after turn-on, to show when the Amplifier is switched to “exciter only,” and to indicate when the thermal circuit breaker has operated. Read the “Kit Builders Guide” for complete information on unpacking, parts identification, tools, wiring, soldering, and step-by-step assembly procedures.ast SS VERY IMPORTANT: BERYLLIUM OXIDE (Be0) CERAMIC BLOCK ‘The ceramic block fitted between the power tube and heat sink is made of high-fired beryllium oxide (BeO). We chose this particular material because of its superior thermal conductivity and high electrical resistivity ~ it is by far the best substance we know of to efficiently transmit the intense heat of the power tube to the heat sink where it is dissipated into the air. While the normal installation and use of this ceramic block is totally safe and will not expose you to any danger, nevertheless, we should caution you that beryllium oxide in its vapor and dust forms is a deadly poison and should never be swallowed, breathed, or brought into contact with the skin or eyes. Under no circumstances should the beryllium oxide ceramic block be drilled, chipped, crushed, sawed, sanded, ground, filed, or subjected to any other dust producing operation, Nor should the block bbe brought into contact with any acid or other chemical solution except as described below. The block should never bbe heated to over 1,000°C (the unit has been designed so that the block will not be subjected to temperatures in excess of 400°C). Should the block become cracked, chipped, or even pulverized or should dust be produced in any other way, Femove the small pieces (and dust) with a wet paper towel. ‘Then discard the towel in a sealed plastic bag. Beryllium oxide dust or particles should never be swept or vacuumed. Should you desire for any reason to remove the filler material used to connect the power tube to the block and the block to the heat sink, do so with a rag dipped in 2 solvent such as lacquer thinner or Varsol. Then discard the rag in a sealed plastic bag. Never attempt to scrape the filler material from the beryllium oxide block. Wash your hands thoroughly after any contact with the beryllium oxide block.ASSEMBLY NOTES MBATHEIT® Each circuit part in this kit has its own component number (R2, C4, etc.). Use these numbers when you want to positively identify the same part in the various sections of the Manual. These numbers, which are especially useful if a part has to be replaced, appear: In the Parts Lists, At the beginning of each step where a component is installed, In some illustrations, In the Schematic, In the sections at the rear of the Manual.CIRCUIT BOARDS PARTS LIST ‘The parts for your Amplifier are in two packs. Remove the pack marked “PK 1’ (pack 1) from the box; remaining parts are pack 2. Check the parts from pack 1 against the following list. You will also need several parts from pack 2, as listed. The illustrations will show you what the parts look like. Only the hardware is drawn to actual size. ‘Some parts are packaged in envelopes with the part number of the contents printed on the outside. Except for the initial parts check, Keep these parts in their envelopes so they can be easily identified when they are called for in the assembly steps. To order @ replacement part, use the Parts Order Form furnished with this kit. If one is not available, refer to “Replacement Parts” inside the rear cover of the Manual. PACK #1 QTY. DESCRIPTION PART CIRCUIT No. Component No. RESISTORS NOTE: The following resistors are 1/2-watt unless otherwise noted. (.) 3 10k@(brownblack- 1-20 R24, 28, 32 orange) (eC 1-22 R26, 27, 29, 31 orange) (.) 1 100k, 2-watt (brown 1-24-2 R22 black-yellow) -=wATHEIT® 7Page 8 QTY. DESCRIPTION PART cIRCUIT No. Component No. OTHER ) 15 1N2071 diode 57-27 1-16 K NOTE: HEATH PART NUMBERS ARE STAMPED ON MOST DIODES. ZWD A, LSPS eeS80S S950 ) 2 MPSA42 transistor 417-204 } 10 Connector pin 432-121 ) — 3_-H2-A neon lamp 412.99 } 1 40 HF capacitor 25-20 PARTS FROM PACK #2 ) 1 Small black steeving 346-1 } 1 Power supply circuit = 85-1440-1 board ) 1 Lamp indicator 85-1589-1 circuit board Solder (Additional 3° rolls of solder, #331-6, ‘can be ordered for 25 ccents each.) NOTE: The prices shown on the separate "Heath Parts Price List” apply only on purchases from the Heath Company where shipment is to a U.S.A. destination, Add 10% (minimum 25 cents) to the price when ordering (Michigan residents add 4% sales tax) to cover insurance, postage, and handling. Outside the U.S.A., parts and service are available from your local Heathkit source and will reflect additional transportation, taxes, duties, and rates of exchange.STEP-BY-STEP ASSEMBLY START Position the lamp indlestor reult boord (G#85-1589-1) with the lttared side up as CONTINUE shown, Then perform the steps on this age. FOR GOOD SOLDER TNOTE® Tstall connector pine (#492-121) CONNECTIONS. YOU MUST in the following locations. Solder each pin KEEP THE SOLDERING oth foi ets install IRON TIP CLEAN. “2 WIPE IT OFTEN pe = With a Camp. Bases Sande OH ELots (CO) R29: 22 KR (ret rad orange) Xt FUL sive of () R28: 10 K2 forown-black orange) CIRCUIT BOARD NOTE: When you instal a transistor, tne ee up the flet on the transistor with the 900000 1) Connector pin at 3 foutine of the flat on the cicult bosd | “Then iset the lads into thei correct E, ors [i> comesoranaz B. and holes. Solder the leads tothe foi LL e—e | aed cut ofthe exes lead eng Wag, { R28, 1040 (brown Blackcorane) Bagg (©) Connector pin at 2 a (R82: 10 k9 tbrown-biack orange) () G2: MPSAG2 (4417-298). The po « sition of the fat is opposite that of ai 4 (0) 31: 22 40 (red-edorange) (Solder the leads to the foil and cut () Ot: mpsaa2 (4417-208) of the exces lead lengths (1 R27: 22 KO (redted-orange), (/} Connector pin a 1. Solder the pin to the fol (R26: 22 KO (red-red orange) I (} Conngetor pin at 4. Solder the pin SAFETY WARNING: Avoid eye injury ta the fail shen you clip off excess leads, We suggest that you weer glases, or at last clip the leads so the ends will not fly toward your PICTORIAL 1 (0) Solder the resistor leads to the foil and cut off the excoss lead lengths marc? ©Page 10 START 1) Out ah lengths of black aleeving 3/4" long. CF Slide 3/4" lengths of black sleeving Conte the six leads of three neon lamps Push the leads of a neon lamp into holes E and F until the sleeving ‘touches the circuit board, Solder the leads to the foil ond cut off the excess lead lengths SMALL NEON LAMP SLEEVING Ql Yim a similar manner, install the ‘second neon lamp in holes Cand D. () Ina similar manner, inetll the third ean lamp in holes and 8. CIRCUIT BOARD CHECKOUT Carefully inspect the circuit board for the following conditions 1) Unsoldared connections ("Cold solder connections Solder bridges between foil patterns Protruding leads. No leads or lugs PICTORIAL 2 be longer than 1/8 ‘Transistors for the proper type and Lay the circuit board aside, Wt wil be instal la FINISHPage 11 CONTINUE <> 7) Postion the vectfir creut Bow (#85-1440-) a shown {Connector pin in hole D. C16: 40 uF electrolytic. Match the plus +" mark on the capacitor to NOTE: In the following steps, be sure to the plus “+” mark on the circuit ‘match each diode band to the band on the board circuit boar. S\. — 4 ir : Instal seven 1N2071 diodes (#57-27) 2s follows ° () 015. + ©) 014 Uy 013. () on Cy on () 08, (1 08. NOTE: DIODES MAY BE SUPPLIED| IW ANY OF THE FOLLOWING SHAPES| ALWAYS POSITION THE BANOED END Testa seven 1N2O71 diodes (#67-27) as follows yor oe D4, () Solder each lead to the fol and cut off the exces lead lengths ps, NOTE: In the following steps, as you Ps install each connector pi, solder i in its ov. hole Solder the leads to the foil and cut off the exces lead lengths { ) Connector pin ia hote Blue CIRCUIT BOARD CHECKOUT | (). Connector pin in hole Red {Connector pin in hole ¢. {)_ Connector pin ia hole 8. Carefully inspect the circuit board forthe following conditions. (1. Uncoldered connections (1 "Cola solder connections. Solder bridges between foil patterns, PICTORIAL 3 Provruding leeds. No leads oF luge should be longer than 1/8 Electrolytic capacitors for the correct patition of the positive (+) ond, () Diodes for the correct postion of the banded end () Lay the circuit board aside, It wil be installed ater. FINISHPage 12 cee aaCHASSIS PARTS LIST Unpack the remaining parts and check each part against the following list. Some parts are packaged in envelopes with the part number of the contents printed on the outside, Except for the initial parts check, keep these parts in their envelopes so they can QTY, —_ DESCRIPTION PART Ne RESISTORS NOTE: The following resistors are 1/2-watt, 10% tolerance, unless otherwise noted. 10% is band of silver; 5% tolerance dicated by a fourth color icated by a fourth color be easily identified when they are called for in the assembly steps. To order a replacement part; use the Parts Order Form furnished with this kit. If one is not available, refer to “Replacement Parts" inside the rear cover of the Manual, CIRCUIT Component No. band of gold. (.) 1 1.8.2 tbrowngreen- 1-140 R25 gold) (.) 1 472 (yellowsiolet- WW R33, black) (1 68092 (blue-gray- 1-82 Ri brown-gold) (.) 1 10008 (brown-black- 1.9 R35, red) () 2 22k (red-red 1-22 R18, 19 orange) (.) 4 100K (brown-black- 1-26 RIS, yellow) wATHEIT® 13Page 14 ary. Other DESCRIPTION 33.9, 1-watt (orange- ‘orange-black) 470 2, t-watt (yellow- violet-brown) 27 kM, 1-watt (red violet-orange) 1500 Q, 2-watt (brown- green-red) 100 kQ, 2-watt (brown black-yellow) TMQ, 2-watt (brown- black-green-gold) 12, 1%, Sewatt 500 0, S-watt 1500.0, 10-watt 100 kM control CAPACITORS Disc 1 1 18 pF .001 pF, 500 volt .001 AF, 6000 volt, 20% 01 uF .01 pF, 1400 volt 02 uF 02 pF, 1600 volt PART No. 144-1 146-1 1142 124-2 131-2 3-255 3315 311-10 10-12 21-60 21-140 21-79 21-16 21-70 21-31 21:38 ciRCcUIT Component No. R17 R16 R36 Rat R3, 4, 6,6, 7,8 R12, 13, 14 Ro R12 R23 R34. C24 C18, 26 co 17, 19, 25, 28,29 1,2 C21, 27, 33 32 \QTY. DESCRIPTION Other () 1 12pF mica () 1 100 pF (100 MME), 000 volt (.) 1.001 2F, 6000 volt (1000 MMF) (.) 1 500 pF mica, 2000 volt () 2 .001 uF feedthrough (.) 6 125 pF electrolytic 1140 pF variable 1 840 pF variable PART No. 20-130 21-109 21-165 21-63 25-34 26-144 26-145 Page 16 CIRCUIT Component No. 4 c22 cia cia 23, 31 3,4, 5,6,7,8 12 cisPage 16 QTY. DESCRIPTION PART cIRCUIT No. Component No. INDUCTORS 1 10-15 moters 40-1665 LI ) } 1 80-40-20 meters 40-1666 -L2 Oy oo4 1.1 mH RF choke (.) 1 8.75 nH RF choke ()o4 13.5 wH Bifilar RF choke () 1 80 gH RF choke () 1 8.5 yH RF Choke () 2 Ferrite bead (1.7 4H) 475-12 FB1,2 NOTE: HEATH PART NUMBERS ARE STAMPED ON MOST DIODES. AAW Am Laas essoang Soe DIODES () 1 11N458 diode 56-24 Dio () 1 1N191 diode 56-26 bis ) 1 1N2071 diode 67-27 D17 a) 1 1N2806A zener 56-609 z01 diode (8.2 volt)ary. DESCRIPTION WIRE AND SLEEVING Wire Sleeving 1 1 1 Bare RG-58A/U Blue Large brown (stranded) Black ‘Small brown (tinned) Red Yellow Violet White White-black White-brown White-red White-yellow White-blue Wire braid Line cord ‘Small clear sleeving Large black sleeving Large clear steeving SWITCHES AND RELAYS 1 1 1 2wafer switch ‘-wafer switch (appearance may differ) Thermal circuit breaker Rocker switch w/breaker Relay Time delay relay Interlock switch PART No. 340-1 343-2 304-13 344-31 344-50 344-34 344-52 344-54 344-57 344-59 344-70 344-71 344-72 344-74 344-76 345-1 89-50 346-2 346-20 346-26 63-700 63-701 65-59 65-53 69-55 69-74 64-24 CIRCUIT Component No. Page 17Page 18 QTY. DESCRIPTION PART No. INSULATORS (yo4 Foam strip 73:39 () 2 Rubber grommet 73-2 () 4 Large plastic grommet 73-45: (.} 2 Small plastic grommet 73-62 () 1 Strain reliet 75-29 (.) 8 Nylon insulator 75-53 () 1 Fish paper 75-68 (.) 1 White insulator 75-701 () 1 Beryttium oxide 75-702 block — (see WARNING on page 4). {) 12 Capacitor mounting 481-3 wafer HARDWARE NOTE: Hardware is illustrated actual size, #2 Hardware () 2 286x 3/8" screw 280-175 () 2 2-66 nut 252-51 () 2 #2tockwasher 254-26 #3 Hardware () 1 3-48 x 7/16" brass screw 250-133 () 4 #3 flat washer 253-94 cIRCUIT Component No.ary. DESCRIPTION #4 Hardware ) 2 440% 1/4" screw ) 6 4.40.x 5/16" screw ) 14 440% 1/2" square head screw Ya 440x1" square head screw Ya 4-40 nut ) 30 #4 lockwasher #6 Hardware ) 1 682x3/16" screw ) 22 632 1/4" screw } 42 632.x 3/8" screw ) 2 632% 3/8" flat head screw ) 4 6321/2" screw } 19 #6x 1/2" sheet metal screw ) 6 632x3/4" screw ) 4 6321" screw ) 2 632% 1-1/2" screw ) 1 6:32x2" screw ) 2 632 spade tug ) 63 632nut ) 2 6-32 Speed Nut* ) 2—-#6 fiber washer ) 2 #6 flat washer ) 64 #6 lockwasher ) 18 #6 solder tug #8 Hardware ) 6 832 1/4" setscrew ) 2 832x3" screw ) 3 #B solder lug *Tinnerman Registered Trademark PART No. 250-52 250-213 250-1194 250-1188 252-2 254-9 250-138 25056 250-89 250-434 250-162 250-1195 250-29 250-13 250-40 250-27 251-7 2523 282-22 253-1 253-60 254-1 259-1 250-43, 250-393, 259-24 CIRCUIT Component No.Page 20 Qty. DESCRIPTION #10 Hardware 10-32 x 1/2" screw 10-24 x 3/4” screw 1032 nut 10-24 nut 10-24 wing nut 3/4" 0.0, flat washer } 2 #10 solder tug )} 5 #10 lockwasher Re+o-+0 Other Hardware Control flat washer Control solder lug Control nut Control lockwasher Spade solder lug wNNorzo Shaft bushing SPACERS ) 1 4.40 x 5/8" tapped spacer ) 218/82" spacer, tapped 6-32 ) 2 —-4-1/4"" phenolic spacer, tapped 6-32 ) 28/16" shoulder spacer, tapped 6-32 ) 217/82" plastic spacer, tapped 6-32 ) 4 3/16" spacer ) 1 4-1/2" spacer PART No. 250-456 250-152 252-5 252-30 252-31 253-19 250-5 254-3 253-10 259-10 2827 254-4 259-22 465-9 285-164 285-23 285-39 286-79 256-152 256-2 256-10 CIRCUIT Component No.oy QTY. DESCRIPTION METAL PARTS 1 Topeabinet shelt 1 Bottom cabinet shell PART Ne 90-1106-1 90-1107-1 CIRCUIT Component No. Page 21Page 22 QTY. DESCRIPTION PART CIRCUIT No. Component No. Metal Parts (cont’d.) 1 RF chassis 100-1633 1 Power supply chassis 200-676a) o) Qty, DESCRIPTION Metal Parts (cont’d.) 1 RF enclosure 1 Left side panel PART No. 200-677 203-1544 CIRCUIT Component No. Page 23Page 24 ay Qty. DESCRIPTION PART CIRCUIT No, Component No. Metal Parts (cont'd) ) 1 Rear panel 203-1646 () 1 Front panet 203-1646-1 () 2 Cover bracket 204-444 (.) 2 Window bracket 204-1918 () 2 Meter bracket 204-1945 () 1 Tube mounting 204-1961 bracket (.) 1 Capacitor bracket 204-2095 {.) 2 Cabinet retainer 205-1576 stripory. DESCRIPTION Metal Parts (cont’d.) a) 1 Lower panel trim strip () 1 Perforated cover () 1 Switch plate () 1 Heat sink TERMINAL STRIPS. G-scrow 3tug 4-lug 2lug ‘lug 4lug Slug Slug Glug PART No. 205-1432-2 205-1536 205-1553 216-74 CIRCUITPage 26 ary. DESCRIPTION Terminal Strips (cont’d.) 2 30-1ug terminal board CONNECTORS 10 4 3 1 1 Female connector Push-on connector Phono socket Spin socket Female coaxial connector Phono plug Coaxial plug Coaxial insert MISCELLANEOUS Roan eae Power transformer ‘Tube plate clamp Rubber foot Black tapered foot Lamp housing Lamp socket Silver plated grid strap Large knob PART cIRCUIT No. Component No. 431-69 432-120 432-137 434-42 434-56 436-5 438-4 438-9 438-12 54-847 n 260-82 261-9 255-59 266-824 434-88 212-45 462-934QTY. DESCRIPTION PART CIRCUIT No, ‘Component No. Miscellaneous (cont'd.) (.) 4 Small knob 462-033 t) 3 Shaft coupler 456-7 (.) 1 43/8" extension shoft 453-35 () 2 4.3/4" extension shaft 45329 ) 1 Diffuser strip 446-644 () 1 Window 446-628-1 () 1 Fusehotder 423.2 () 1 3/4 ampere, 3AG 421-29 FI slow-blow fuse cy 1 #1820 lamp 412-47 PLI () 1 Lamp shield 206-86 () 1 Type e873 tube.Be = 411-298 VI sure to save the tube manufacturer's warranty packed with the tube. () 1 Meter 407-185 MT () 2 Cable tie 354-6 () 3 ‘Thermal compound 352-31 pod () 1 Nat starter 4905 () 1 ‘Wrench 490-168 PRINTED MATERIAL () 1 Danger tabet 390-147 () 1 Blueand white label 391-34 (1 Parts Order Form 597-260 () 1 Kit Builders Guide 597-308 {) 1 Manuat (See front cover e > for part number.) NOTE: The prices shown on the separate “Heath Parts Price % = n9. where shipment is to a U.S.A. destination. Add 10% (minimum 25 cents) to the price when ordering (Michigan residents add 4% sales tax) to cover insurance, postage, and hhandling, Outside the U.S.A., parts and service are available from your local Heathkit source and will reflect additional sransoortation. taxes, duties. and rater nf avah=—==“STEP-BY-STEP ASSEMBLY The illustrations in this section of the Manual are called Pictorials and Details. Pictorials show the overall operation for a group of assembly steps; Details are used in addition to the Pictorials to illustrate a single step. When you are directed to refer to a certain Pictorial “for the following steps,” continue using that Pictorial until you are referred to another Pictorial for another group of steps. As the drawings in the Manual may be slightly distorted to show all the parts clearly, look at the “Chassis Photos" (Page 109) from time to time to see the actual positions of wires and components. Lockwashers and nuts will be used with most screws when you are mounting parts, unless the assembly steps state otherwise. Consequently, the applicable steps will call out only the size and type of hardware used. For example, the phrase “Use 6-32 x 1/4” hardware" means to use 6-32 x 1/4" screws, one or more #6 lockwashers, and 6-32 nuts. Refer to the Details for the proper installation of hardware. Be sure to position each part as shown in the Pictorials Follow the instructions carefully, and read the entire step before performing the operation. ‘When a step directs you to “connect” an insulated wire, first prepare its ends by removing 1/4” of insulation. 29Page 30 RF CHASSIS () Refer to Detail 48 and mount a 6-lug terminal strip in Q—sse wr hole TC. Use 6-32 x 3/8” hardware and a #6 solder lug (under the screw head). S| 3/8" hardware, DO NOT use a solder lug with this, fh ‘terminal strip. & i (Refer to Detail 4C and mount a small plastic grommet #6 LOCKWASHER in hole CL. Be sure the grommet is seated flush against the chassis. Detail 4A, POSITION THE SMALL BEND THE LARGE PORTION PORTION OF THE GROMMET OF THE GROMMET OVER AND INTO THE CHASSIS HOLE TO. THE SMALL PORTION PRESS IT FIRMLY INTO Detail Lace Refer to Pictorial 4 on Page 31 for the following steps. se NOTE: Use the nut starter provided with this kit to hold 6-32 NUT and start 6-32 and 4-40 nuts on screws. ° #6 LocKWAsHER () Refer to Detail 44 and mount a 6-lug terminal strip in an tie 3/8" hardware. Position the terminal strip as shown [reeniitt Some] and then tighten the screw from the top side of the chassis. This is terminal strip TA. #6 LOCKWASHER: S55 pe one we ces ee Detail 4D & 6-32 13/8" soREW fe LocKMAsHER Refer to Detail 4D for the following two steps. #6 LOCKWASHER () Cut off the lug shown. Be sure you select the correct lug. S pusouaee (|) Mount the 4-lug terminal strip in hole TE. Use 6-32 x 4 6-32 x 3/8" SCREW 3/8” hardware with a #8 long lug (under the screw head). Detail 4BPage 31 () Refer to Detail 4E and mount a 15/32” long spacer at hole CP. Use a 6-32 x 1/4” screw. © és Lockwasner { ) Similarly, mount @ 15/32” long spacer at hole CN with i 46-32 x 1/4” screw. Detail 4E PICTORIAL 4 —1s. 470.10 PICTORIAL 5 Refer to Pictorial 5 for the following steps. UPPER HOLE Nott She. 1. You will be instructed to insert component leads and oo wires into the “lower” holes of terminal strip lugs in Roernihete some of the following steps. Detail 5A shows the “tower” and the “upper” hols of the terminal stip solder lugs. Always use the upper holes unless you are SSL specifically instructed to use the lower holes. Detail 54 2. When you are instructed to “push a lead down against the insulator strip,” position it as shown in Detail 5A. For clarity, the following Pictorials will usually show the position of components after they have been 3. Save four of the capacitor leads that you cut off in the mounted; other parts, not shown, may have been following steps. They will be used to wire socket V1. Previously mounted. pp er tlt ep el |OVE EXCESS COATING Detail 5B Before you install a disc capacitor, refer to Detail 5B and remove any excess coating from its leads by exerting a small amount of pressure with pliers and then twisting the lead. This excess coating could otherwise interfere with soldering when a capacitor is installed with very short leads. 6. To “prepare” an insulated wire, cut it to the specified length and then remove 1/4" of insulation from each end. If the wire is stranded, twist the fine strands at each end tightly together and then melt a minimum amount of solder on the bare wire, To avoid confusion with lower voltage capacitors, temporarily lay aside the following high voltage disc capacitors. Use them only when these voltage ratings are specified in a step: 1.001 pF, 6000 volt (6 KV) disc capacitor 2.01 MF, 1400 volt (#21-70) disc capacitor 1.02 pF, 1600 volt (1.6 KV) disc capacitor (Prepare a 1-3/4" yellow wire. () Connect the yellow wire to terminal strip TA between ug 3 (NS) and lug 5 (NS). Push the wire down agsinst ‘the insulator strip. Page 33 () €24: Connect an 18 pF disc capacitor to terminal strip TA from tug 2 (NS) to lug 3 (NS). () C25: Connect a .01 uF disc capacitor to terminal strip TA from lug 3 (NS) to lug 4 (NS). NOTE: When a wire passes through a connection and then ‘goes to another point, as in the next step, it will count as ‘two wires in the solder instructions (S-2), one entering and ‘one leaving the connection. Be especially careful, when soldering these connections, to apply enough solder and heat to solder these “through wires.”” () R17: Connect one lead of a 33 9, I-watt (orange-orange-black) resistor to socket V1. Push the lead through lug 11 (S-2) to lug 4 (NS). Connect the other lead of this resistor to terminal strip TC. Push the lead through lug 5 (S-2) to lug 6 (NS). NOTE: Use the four cut-off capacitor leads for wiring socket V1 in the following steps. () Form a small hook at one end of a cut-off capacitor lead. Place this hook over the midpoint of the wire in the preceding step (S-1). Connect the other end of this, wire to lug 7 (S-1) of the socket. () C17: Connect a .01 uF disc capacitor to terminal strip ‘TC between the lower hole of lug 2 (NS) and the lower hole of tug 3 (NS). () C19: Connect a .01 uF disc capacitor to terminal strip TC between the lower hole of lug 3 (S-2) and the lower hole of lug 4 (NS). () R25: Connect a 1.5 2 (brown-green-gold) resistor to terminal strip TC between the lower hole of lug 2 (S-2) and the lower hole of lug 4 (S-2). () R16: Connect a 470 9, 1-watt (yellow-violet-brown) resistor to terminal strip TC between lugs 4 (NS) and 6 (NS). () €29: Connect a .01 HF disc capacitor to terminal strip TE between the Jower hole of lug 1 (S-1) and the lower hole of lug 3 (NS). (C28: Connect a .01 yF disc capacitor to terminal strip TE between the lower hole of lug 2 (S-1) and the lower hole of lug 3 ($2).Page 34 PICTORIAL 6 Reter to Pictorial 6 for the following steps. ) Connect a cut-off lead between socket lugs 1 (S-1) and 8 (S-1). Before soldering, curve this wire up at its midpoint so it clears the wires below it by at least 118". ) Connect a cut-off lead between socket lugs 2 (NS) and 9 (S-1). Position this wire so it passes over, and touches, the wire in the preceding step. ) Connect a cut-off lead between socket lugs 3 (S-1) and 10 (S-1). Position this wire so it passes over, and touches, the wire in the preceding step. ) 19: Connect the lead at the unbanded end of a type 1N458 diode (#56-24) to terminal strip TA lug 2 (NS), and connect the lead at the banded end to lug 3 (sa), ) €26: Connect a .001 uF disc capacitor to terminal strip TA from lug 5 (S-2) to lug 6 (NS). ) R19: Connect @ 22 kM (red-redorange) resistor to terminal strip TA from lug 4 (NS) to lug 6 (NS). ) RIB: Connect 2 22 kA (red-red-orange) resistor to terminal strip TA from lug 2 (NS) to lug 4 (S-3). } 22: Connect one lead of a 12 pF mica capacitor to ‘terminal strip TA lug 2 (S-4). Connect the other lead to socket V1 lug 4 (S-2). =< Prepare two 3” lengths of large brown (stranded) wire, Then refer to Detail 6A and form the two wires into a twisted pair. ‘At one end of the twisted pair, connect one wire to socket V1 lug 5 (S-1), and connect the other lead to lug 6 (S-1), Connect the other end of the twisted pair to terminal strip TD: one wire to the lowor hole of lug 1 (S-1) and. the other lead to the lower hole of lug 2 (S-1) RFC 4: Connect one lead of an 8.5 wH RF choke (45-6) to terminal strip TD lug 4 (NS). Wrap the other lead of the choke around the three wires which cross at the midpoint of socket V1. Solder all four wires together. NOTE: In the following step, position the RF choke so it clears the chassis by 1/4”. Its position must also permit insertion (later) of a 6:32 screw in hole CM. O) RFC 3: Connect the two leads at one end of a 13.6 zH RF choke (#45-58) to terminal strip TE lug 1 (NS) and lug 2 (NS). Connect the two leads at the other end of the choke to terminal strip TD lug 1 (NS) and lug 2 (NS). Make sure the choke is positioned as described in the note, 2 3= Refer to Pictorial 7 for the following steps. nt () 32: Connect a .02 yF, 1.6 kV, disc capacitor from socket V1 lug 2 (5-2) to terminal strip TA tug 1 (NS). Position this capacitor as shown. It must clear the chassis by 1/4" to allow passage of a coaxial cable to be installed later. Push the lead on lug 1 down against the insulator strip. (1) C27: Connect a .02 uF capacitor to terminal strip TD between lugs 1 (S-2) and 2 (S-2) () €33: Connect a .02 uF disc capacitor to terminal strip ‘TD between lugs 3 (S-1) and 4 (NS). Detail 7B () Refer to Detail 7B and cut out a piece of fish paper 21/2" x3". RE CHOKE () Remove and discard the protective cover from the gray fish paper. Then, with the adhesive side toward the chassis, butt the 2-1/2" edge against the spacers at CN and CP and center the paper between holes CH and CJ. Then lower the paper and rul place against the chassis. it firmly into : LE. 8.75 wH RF choke (#45-42) toward the slot in the Yy yy coil form, Then connect the RF choke to terminal Yj strip TC between lugs 4 (NS) and 6 (S-3). j () R33: Connect a 47 2 (yellowviolet-back) resistor to terminal strip TC between lugs 1 (NS) and 4 (S-3) PICTORIAL 74 2 6 8 AIRUSIa-Vallavell 1500 ff soo ff 00 ls Jar HOM? pf tae Fo f Sy ee tae tae ats 21 117 ng 23 sien PICTORIAL 8 Refer to Pictorial 8 for the following steps. 4and 19 10 and 25 Gand 21 12and 27 Band 23 (} Place @ 30-1ug terminal board before you and observe how the slots are numbered, Solder the leads to the terminals, but do not cut off any excess leads yet. () Refer to Detail 8A for the following three steps. Place five 1800 9, 2-watt (brown-green-red) resistors with their leads in the following pairs of numbered slots. () CAUTION: Cut off the excess lead lengths ONLY at ‘terminals 4, 6, 8, 10 and 12. 1500 11 1500 wth aw Detail 84.( Place two 1500 2, 2-watt (brown-green-red) resistors with their leads in the pairs of slots at 2 and 17 and at 14 and 29, Solder the leads. DO NOT cut off the leads yet. Refer to Detail 8B and cut the resistor leads at terminals 17, 19, 21, 23, 25, 27 and 29 to 3/8" from the terminals. 1500 FF gyn a aI i they Refer to Pictorial 9 for the following steps. () On the remaining 30-lug terminal board, place six of the 1500 ©, 2-watt (brown-green-red) resistors in the following pairs of numbered slots. Solder the leads. Band 18 Q and 24 Sand 20, 11 and 26 7 and 22 13 and 28 () CAUTION: Cut off the excess lead lengths ONLY at terminals 18, 20, 22, 24, 26 and 28. Place two of the 1500 2, 2-watt (brown-green-red) resistors with their leads in the pairs of numbered slots at 1 and 16 and at 15 and 30. Solder the leads. DO NOT cut off the leads. Cut the leads at terminals 1, 3, 6, 7, 9, 11, 13 and 15 to 3/8" from the terminals. 9 WW FI UT df PICTORIAL 9= eFesFssSSSSSS—S— Refer to Pictorial 10 for the following steps, () R21: Refer to Detail 10A and mount the 30-ug SeeaSseano| Lrenmivae terminal board with seven resistors at hole CD and spacer CN, Position terminals 1 and 16 of the circuit board toward the spacer. Use a #6 solder lug and a 6-32 x 1/4" screw at spacer CN. At hole CD, use a 6-32 x 3/8” serew inserted from the other side of the chassis, a #6 fiber washer, a #6 solder lug, and a 6-32 nut, () R18: Refer to Pictorial 10 and Detail 108, Position the remaining 30-lug terminal board so its mounting holes are aligned with spacer CP and hole CE, its lugs 1 and 16 are toward the spacer, and the 3/8” lead of each resistor rests in the matching slot of the other terminal board, as shown in the Pictorial. Mount the terminal board with a #6 solder lug and a 6-32 x 1/4" serew in spacer CP. At hole CE use a #6 solder lug, a #6 fiber washer, a 6-32 x 3/8” screw, and a 6-32 nut, {} Solder the remaining 16 unsoldered 3/8” resistor leads along the two middle rows of terminals, Let the solder Tun out onto the resistor leads between two center rows of terminals, as braid will be soldered to these leads later. Solder the four leads at the ends of the terminal boards to the four #6 solder lugs. Cut off the excess lead lengths. Refer to Detail 10C and its inset drawing for the following ‘two stops. (1) Cuta 4-1/2 length of wire braid () Open the end of the wire braid with a sharp instrument, such as the point of a knife blade (the braid is actually flattened, tubular braid). Slide the ‘open end of the braid onto lug 1 of terminal strip TA, (62) Position the other end of the wire braid between the ‘two middle rows of terminals and solder the braid to ‘the 15 resistor leads. Use plenty of heat and solder. Check to make sure the braid is well soldered to the leads, PICTORIAL 10 went) 2 3 4 5 6 7 ey6-32 Lar screw [ 4-12 Wine BRAID Pew 0 <—ooe a Detail 104, Detail 10¢ ay soem A) #6 sovoer Luc ooze > staewe 40, sHouLoer SPACER —@ 632 13/8" SCREW Detail 114 Rafer to Pictorial 11 for the following stops. () Refer to Detail 11/4 and install two spade lugs on the bottom of the 80-40-20 meters coil. Use a 6-32 x 3/8” serew, a #6 lockwasher, and a 6-32 nut for each spade lug. There are three holes at the large winding end of the coil form. Install the spade lugs in the two holes counterclockwise from the end of the coil when viewing the coil from the bottom. Note the position of the offset in the spade lugs. With the larger end toward the coil, screw a 3/16” shoulder spacer (tapped 6-32) onto each spade lug as far as it will go, se arse BARE WIRE WINDING Detail 118 (.) Refer to Detail 118 and position the coil with the large winding at the bottom, as shown, Push a 6-1/4” bare wire through the solder lug at 80 until the end of the wire is exactly 3” from the lug. Solder the wire to the tug, L2: Refer to Detail 11C and mount the 80-40-20 meter coil at holes CG and CH. Use a #6 lockwasher and a 6:32 nut for each spade lug, Be sure the coil taps are facing directly away from the tube socket as shown in Pictorial 14, NOTE: In the following step, refer to Pictorial 11 inset drawing and to Detail 11F for the location of hole CB. 0) (.) Refer to Detail 11D and install a #6 solder lug at hole CB. Use a 6-32 x 1/4” screw and a 6-32 nut. Bend the solder lug up as shown. Solder a 2” bare wire to the solder lug COLL TAP 6 husecen 6S NOTE: Refer to Detail 11E for the numbering of the wafer switch solder lugs (SW3), as viewed from the rear. ‘There are two switch lugs, one on each side of the wafer, at each position. Always solder a wire or lead to both lugs, and flatten the end of the wire with pliers so it will easily slides into the switch solder lugs. 632 NUT Detail 11¢ () C14: Refer to Detail 11E and mount a 500 pF mica capacitor (may be marked .0005) on the 2-wafer switch (SW3) between wafer 1 lug 1 (NS) and water 2 lug 1 ($1). ements) 2 aCONTROL NUT 6-32. NUT #5 soLveR Luc Detail 11D Detail 11E () SW3: Refer to Detail 11F and mount the 2-wafer switch in hole SW3. Use a control lockwasher, a control, flat washer, and a control nut. Be sure to position the switch lugs as shown, As you position the switch, insert the end of the bare wire (coming from solder lug CB) between the two lugs of wafer 1 lug 1. After the switch is mounted, solder together the two switch lugs, the capacitor lead, and the bare wire, Cut off any excess length of bare wire, ° Detail 11F PICTORIAL 11Detail 13FPICTORIAL 12 Refer to Pictorial 12 for the following steps. CAUTION: Switch SW3 will be wired in the following steps. ‘The lerge bare wire is stift and the ewitch lugs can be easily bent. Therefore, DO NOT bend the bare wire with one end connected to the switeh lugs, or the switch will probably be damaged. Form each wire so it fits, put it in position, and solder it in place. Flatten the ends of the wires with pliers so they will entor both switch tugs at each position, (Connect the 3-1/4" bare wire trom the 80 coil tap to SW3 lug 6 (8-2). Inthe following steps, connect bare wires from tho designated lugs of wafer 2 of switch SW3 to the designated coil terminals, { see ue ‘senew a Detait 134, Refer to Detail 13A and install the 100 pF 5 KV ‘capacitor {may be marked 100 MMF} on the capacitor bracket with 2 632 x 1/4” screw. Use the smaller ote. C13: Refer to Detail 138 and mount the capacitor and bracket assembly on bolt BB on the shaft end of the 140 pF variable capacitor (#26-144). Use a 10-32 nut, If necessary, bend the bracket so the capacitor body does not touch any part of the band switch. Wire ‘Switch Coil Lug Terminal a 242 isa) 40181) a 23/4" 4(S2) 20(S-1) Oy 3” 3(S2} 16 (NS) Detail 138 Refer to Pictorial 13 (fold-out from Page 42) for the following stops. ou mh 1 mene 2 3 “ 5 6 7 emane ents i 1 i al H Joe be bees opts shoe ee ode ce eae Ww ewPage 43 2 Loop FLaTTEN Detail 13D. 2 wie Thy v caraciron Detail 13E (} Refer to Detail 13E and solder a 2” length of wire braid to the tab on the 10-15 meter coil, L1. Refer to Detail 13F (fold-out from page 42) for the next five steps, Bs-32 nur () Liz Place two #6 flat washers and the solder lug of the 10-15 meter coil over stator plate screw BA of variable capacitor C12. Secure the solder lug with a 6-32 nut. #6 LOCKWASHER ® to both the subpanel and the chassis, and so the fre end of the coil butts against the solder lug at L2 coil terminal 16 (S-2). Detail 13¢ 1) Position the wire braid coming from the 10-15 meter coil tap so the braid passes between the two terminals, at lug 2 of switch SW3. Solder the braid to both () C12: Refer to Detail 13C and install the 140 pF i ‘terminals. Variable capacitor (#26-144) at holes CA and CF with its shaft in subpane! hole C12. Use 6-32 x 3/8” hardware at each mounting hole. (} After the braid is connected and soldered, melt enough solder into the braid between the two connections to stiffen { } Refer to Detail 13D and make a loop in the end of a 2" wire to pass a 6-32 screw. Flatten the other end so ( ) C11: Install a 001 uF ceramic capacitor (may be it will enter both terminals of an SW3 switch lug. marked 1000 MMFD) on the stator bolt of variable capacitor C12 at BA, Turn the tapped capacitor snugly () Connect the wire loop to the remaining terminal of onto the bolt (the capacitor threads are 6-32). 13, the 100 pF ceramic capacitor. Use 2 6-32 x 1/4” serew. Solder the other end of the wire to SW3, wafer ( } Install a #6 solder lug at BE on the other end of the #1, lugs 2. ceramic capacitor. Use a 6-32 x 3/16" screw.Page 44 8409 SHAFT VARIABLE ND CAPACITOR 426-185 Refer to Detail 14A for the next two steps. {} Mount a #6 solder lug on the rear frame of an 840 pF vafgle capacitor st BC. Use a 6-22 x 1/4" sre D After tightening the sre, bond the solder lug soit points tote rea. (_ ) Install two #10 solder lugs on the stator bolt of the 840 pF variable capacitor (#26-145) at BD. Use a 10-32 nut. Bend both lugs as shown. () C15: Refer to Detail 148 and mount the 840 uF HP CH Soroeeese Detail 144 variable capacitor at holes CC and CJ with its shaft in nae subpanel hole C16, Use 6:32 x 3/8” hardware at each Senew mounting foot. e323) (Solder the free end of the bare wire coming from the fower coil terminal to a solder lug at BD on variable capacitor C15. Be sure the wire does not touch any of the coil turns. VARIABLE CAPACITOR #26145 ts vocxmasnte @D vse wi C15 between solder lugs BC (NS) and BD (S-1). If the coil form has a slot, bend the choke leads toward the slot. At BD, wrap the lead of the choke around the solder lug. When you solder this lead, do not allow solder to flow into the hole in the end of the solder lug. F “() RFCS: Refer to Detail 14C and mount 1.1 mH RF x choke (#45-4) on the rear frame of variable capacitor () RFC2: Refer to Detail 14D and install a 50 yH RF choke (#45-61) at CM. Use a 6-32 x 3/8” screw with a #6 lockwasher under the screw head. Be sure the bottom lug is positioned as shown in the Pictorial. Do ‘ot overtighten the screw, 3 4Page 45 Detail 14C © ps rccreasuen (C8: Cut the leads of a .001 uF, 6 kV, disc capacitor to 1/2", Connect the capacitor from solder lug TC (S-1) Detail 14D. S32 4318" screw to the bottom lug of RFC2 (NS) TP. PICTORIAL 14Page 46 RF ENCLOSURE 6-32 1318" FLAT HEAD Scgew — Detail 154 Refer to Pictorial 15 for the following steps. () Refer to Detail 15A and install a switch mounting plate at SW1 on the inside of the RF enclosure. Use 6-32 x 3/8" flat head screws, #6 lockwashers, and 6-32 nuts at holes AU and AX. THS1OE OF RF ENCLOSURE L ) SWI: Refer to Detail 188 and install the rocker switch at SW1. Be sure the words OFF and ON are positioned correctly. Then push the switch into the opening until both spring catches snap into place. BEND THE LARGE PORTION OF THE GRONMET OVER AND INTO THE SMALL PORTION. PRESS IT FLRMLY INTO PLACE POSITION THE SMALL PORTION OF THE GROM INTO THE ENCLOSURE HOLE Detail 15¢ ) Refer to Detail 15C and install a large plastic grommet in hole BN on the left side of the RF enclosure. Seat the grommet firmly in place. ) Similarly, install a large plastic grommet in hole BF. ) Similarly, install a small plastic grommet in hole BG Con the left side of the RF enclosure. ) Refer to Detail 15D {fold-out from Page 47) and attach the RF enclosure to the RF chassis, Use #6 x 1/2" hex head sheet metal screws at BJ, BL, and BM on the left side of the RF enclosure, and at holes AN, AP, and AS on the right side of the chassis, ) Set the RF enclosure aside. It will be assembled later. Detail 15B o ~~ % 1 omens 2 3 Lee ae em Hi Dt ob ccm E TePICTORIAL 15.Detail 15DPICTORIAL 20APage 48 Saas) POWER SUPPLY CHASSIS () Refer to Detail 166 and place a control solder lug and a control nut on the 100 k&2 control (#10-12), Form ‘the solder lug so it touches lug 1 of the control and solder the two lugs together. Then remove the control rut. contROt MoT POSITION THE SMALL BEND THE LARGE PORTION conrrot PoRtlaN OF THE CROMMET OF THE GROMIAET OVER AND HAT WASHER WTO THE CHASSIS HOLE INTO THE SMALL PORTION. PRESS IT FIRMLY INTO Detail 16A Lace Refer to Pictorial 16 for the following steps, () Refer to Detail 16A and install a large plastic grommet in hole BC on the power supply chassis. conteot NUT @) conor FLAT WASHER contro Detail 16D. () R34: Refer to Detail 16D and mount the 100 KS control at R34 with a control flat washer and a control nut. THIS LUG. POINTS STRAIGHT conTROL LOCKWASHER na 6-32 13/8" screw Detail 166 () SW2: Refer to Detail 168 ond mount the t-wafer switch at SW2 on the power supply chassis, Be sure to ee “ position the color dot on the edge of the wafer as #9 LOCKWASHER shown. All switch wiring is keyed to the position of [ia] ip this color dot. Use a control lockwasher, a control flat [et na washer, and a control nut. LOCKWASHER aa, o o* 6-32 wut roots BY uN CONTROL 2 wer , nT Detail 16 or conTagt sue {) Refer to Detail 166 and install a long lug on top of the ‘chassis and a one-lug terminal strip below the chassis, emeaaeE at hole DE, Uso 6-32 x 3/8” hardware, taiPage 49 Saves sre aier sent B Ho LocKWasHeR ps Ho Locenasuen @ Detail 16F Detail 16H (0), Refer to Detail 16F and install a 6ug terminal strip at " DD. Use 6-32 x 3/8” hardware. (} Refer to Detail 16H and install @ rubber grommet in hole DT. ()- Install a large plastic grommet in hole EC. 4-40 x 5/18 screw aeND OUT SLIGHTLY @ #4 cockwasuer b 4-40 NUT Detail 166 (.) Refer to Detail 16G and install a 9-pin socket in hole EA from the underside of the chassis. Use 4-40 x Detail 16) 5/16" hardware. Position the opening between the lugs 1 and 9 toward the front of the chassis. (.) Refer again to Detail 16G and bend the lugs of the (_) Refer to Detail 16J and install a rubber grommet on Spin socket out slightly. the right side of the chassis in hole EN,si aes = Refer to Detail 16K for the next 3 stops. CAUTION: Do net overtighten the hardware used with phenolic spacers. () Mount a phenolic spacer at DX with a #6 solder lug. Use 6-32 x 3/8” hardware, () Mount a phenolic spacer at DZ with #6 solder tugs above and below the chassis. Use 6-32 x 3/8” hardware. ss cocxasmeed> cue g () Install a #6 solder tug at DY. Use 6-32 x 1/4” ScREW & hardware. Sete" abn sovoee we (-)- RY: Refer to Detail 16L and install ¢ relay (#69-55) on a spacer, and a 3ug terminal strip at hole EB. Use Goro senew 6:32 x 2” sorew, a Sug terminal strip, @ 1-1/2" spacer, a #6 solder lug and two #6 lackwashers. Detail 16K CAUTION: Handle the relay carefully while you assemble the remainder of the chassis, Refer to Pictorial 17 for the following steps. () Rt: Connect a 500 2, S-watt resistor to terminal strip DD between tugs 1 (NS) and 4 (NS) (} R2: Connect a 600 2, 5-watt resistor to terminal strip s #6 SOLDER LUG DD between tugs 2 (NS) and 5 (NS) NOTES: meeiersern 1, ‘The wiring of the subpanel is done before the six filter capacitors are installed. However, when you run wires to other components, keep in mind that the wires must pass around the ends 6 LOCKWASHER of the group of six large holes so they will not interfere with the capacitors, which will be installed later. &: 20 21 22 COLOR 63202" Screw © detail 161. Kho % % 1 cones) 2 3 4 5 6 7 ° febterapeeer et va 1 1 4 1 4 fu obteant Sse ee UU a2. Refer to Detail 17A for the numbering of switch (} Prepare the following lengths of wire. The wires are ‘SW2 solder lugs. Every hole in the switch wafer listed in the order in which they will be used. is numbered, whether @ switch terminal is installed or not. Four lugs are located on the VW" red 21" yellow front side of the wafer (toward the subpanel) 20" red 41” yellow 5" whiteed 17" whiteyellow 3. When a step calls for a twocolor wire, such as ‘‘whiterted,” the wire will have @ white body () Solder a female connector to one end of an 11” red with a red stripe. wire. Connect the free end of the 11” red wire to 4. When you attach female connectors to wires, use sedtet] SW2lu9 19.151), ‘a minimum amount of solder so it will not flow into the end of the connector. } Connect one end of a 20" red wire to switch SW2 lug ( 21 (S-1). Position this wire along the edge of the oA chassis, under control R34, and then back toward the rear of the chassis. () Connect one end of a 6" white-red wire to switch SW2 ug 12 ($-1). Femaue connector () Connect one end of a 21” yellow wire to switch SW2 lug 10 (S-1). Position this wire along the edge of the chassis, under control R34 and then back toward the rear of the chassis. () Solder @ female connector to one end of the 11” yellow wire, Detail Ze) () Connect the free end of the 11” yellow wire and one () Refer to Detail 17B and prepare an 11” violet wire. end of a 17” white-yellow wire to switch SW2 lug 8 Solder a female connector 10 one end of the wire, (2), Push the other end of the 17” white.yellow wire ‘Connect the other end to switch SW2 lug 16 (NS). down through grommet DC. Fema cownecrors. PICTORIAL 17Fae 2 SS PICTORIAL 18 Refer to Pictorial 18 for the following steps. () Connect a 1-1/2" black wire to switch SW2 between lugs 9 (S-2) and 3 (NS) () Prepare the following lengths of wire: () Connect one end of a 3-1/2" black wire to switch ‘SW2, lug 3 (S-2). Connect the other end to the control, 2" black 22" white-blue solder lug at lug 1 of control R34 (S-1) 1-1/2" black 6-1/2" red 3-1/2" black {} Connect one end of a 22” white-blue wire to switch ‘SW2 lug 6 (S-1), Push the other end of the wire down through grommet DC. {) Remove an additional 1/4” of insulation from one end of a 2” black wire, Push this end through switch SW2 {) Connect one end of a 6-1/2" red wire to switch SW2 tug 11 (S-2) to lug 9 (NS). Connect the other end of tug 14 (S-1). Push the other end of the wire down the wire to lug 18 (S-1), through grommet DC. OK ym 1 memes) 2 3 4 ° 1 febeaceiees el L Poi oud 1 pete bt oe tet be BO Be aPage 63 PICTORIAL 19 Refer to Pictorial 19 for the following steps. OO Prepare the following lengths of wire (be sure to use the small brown wire, which is tinned). 22" violet 10” white-brown 9-1/2" white-black 4" black 8-1/2” small brown (tinned) 8-1/2" small brown (tinned) Connect one end of a 22” violet wire to switch SW2 lug 16 (S-2). Push the other end of this wire down through grommet DC. Remove an additional 1/4” of insulation from one end of a 10” white-brown wire. Push this end through switch SW2 lug 20 (S-2) to lug 22 (S-1), Connect the other end of this wire to control R34 lug 2 (S-1) Connect one end of a 9-1/2" white-black wire to switch SW2 lug 7 (S-1). Push the other end of the wire down through grommet DC. ( ) Connect one end of a 4” black wire to switch SW2 lug ) 18-1) Refer to Detail 19A and form a “twisted pair” with the two 8-1/2” brown wires. Connect one end of the twisted pair to terminal strip DD: one wire to lug 4 (8-2) and the other wire to lug 5 (S-2). TWISTED PAIR Detail 194Page 54 Refer to Pictorial 20A (fold-out from Page 48) for the following steps. () R36: Connect a 1000 © (brown-black-red) resistor to ‘terminal strip EB between the lower holes of lugs 1 (S-1) and 2 (S-1) () C21: Connect a .02 uF disc capacitor to terminal strip EB between lugs 2 (NS) and 3 (NS). (:) 18: Connect the lead at the banded end of a 1N191 diode (456-26, brown-white-brown) to terminal strip EB lug 3 (NS); and connect the other lead to lug 1 (ws). () Prepare a 15" white-brown wire. Connect one end to terminal strip EB lug 3 (S-3) and the other end to control R34 lug 3 (S-1). () Prepare @ 6-1/2” black wire and solder a female connector to one end, Connect the other end to ‘terminal strip EB lug 2 (S-2). NOTE: Refer to the inset #1 drawing of Pictorial 20 for lug numbering of RY1. Refer to inset drawing #2 for the detail of wiring terminal strip EB. () R96: Cut one of the leads of 2 27 KS, 1-watt {red-violet-orange) resistor to 1” and the other lead to 3/4”, Place a 3/4” length of small black sleeving on the 1” lead and connect the lead to lug 7 of relay RY1 (NS). Connect the other resistor lead to terminal strip EB lug 1 (S-2). Provide at least 1/8” clearance between the resistor lead and relay lug #9. Lele" BARE WIRE Detail 20A-1 () Refer to Detail 20A-1 and form a 1-1/2" length of bare wire so it will fit between lugs 1 and 3 of retay RY1, Solder the wire to each lug. Cut off any excess wire which protrudes down toward the relay lugs immediately below. Oo % % % 1 memes 2 3 fms iee tet L (). Prepare the following lenaths of wire: 9” white 13” white 5-1/2" large brown (stranded) () Solder a female connector to one end of a 9” white wire, (} Connect the other end of the wire to relay RY1 lug 11 (Ns) () Connect the red wire coming from switch SW2 to relay RY1 lug 11 (NS). () Connect one end of 2 13” white wire to relay RY1 lug 12 (NS). Push the other end of this wire down through grommet EC. () Connect one end of a 5-1/2" large brown (stranded) wire to the solder lug under the spacer at DX (NS). Refer to Pictor following two steps. 20B (fold-out from Page 48) for the (} D17: Refer to Detail 208 and place a 1” length of small black sleeving on each lead of a 1N2071 diode (#57-27). Connect the lead at the banded end of the diode to lug 12 of relay RY1 (NS), Position the diode back of the relay and connect the other lead to lug 11 (NS). (} R23: Place a 1-1/4" length of small black sleeving on each lead of a 1500 92, 10-watt resistor. Position the resistor above relay RY1 and connect it to relay lugs. 12 (NS) and 11 (S-4). Dee rocrwaswen 5= Refer to Pictorial 21 for the following steps. () Refer to Detail 21 and install a screw terminal strip ‘on the two phenolic spacers. Use 6-32 x 1/4” screw and #6 lockwashers, () Cut a 20-1/2" and a 19” large brown (stranded) wire, DO NOT remove any insulation yet. Insert these wires into a 16” length of large black sleeving. Then remove 1/4” of insulation from the ends of each wire and melt 2 minimum amount of solder on the small strands at the wire ends. Detail 21¢ Refer to Detail 21C for the following two steps. () Ct: Connect a 01 pF, 1400 volt disc capacitor (#21-70) between 6-screw terminal strip lug 1 (S-2) and solder tug DX (S-2). Detail 218 SLEEVING () C2: Connect a .01 WF, 1400 volt disc capacitor {}) Refer to Detail 218 and connect one end of the pair between 6-screw terminal strip lug 5 (NS) and solder of large brown (stranded) wires to G-screw terminal lug 02 (8-1). strip lugs 1 (NS) and 2 (NS). () Prepare a 17" and @ 16” small brown (tinned) wire and form a twisted pair (approximately one turn in ‘two inches). Connect one end of the twisted pair to terminal strip DD lugs 1 (S-2) and 2 (S-2). Connect the other end of the twisted pair to 6-screw terminal strip lugs 2 (S-2) and 4 (NS). o-screw TERMINAL STRIP SMALL BRN - PICTORIAL 21 —=——Faue 66) aa TU TERMINAL'STRIP) Detail 224 Refer to Pictorial 22 (fold-out from Page 59) for the lowing steps. following steps. Detail 22¢ (_). Refer to Detail 22 and, from the top of the chassis, press eight nylon insulators into the holes in the power supply chassis at DF, DG, DH, DJ. DK, DL, DM, and DN. Push the insulators down against the chassis as far ( ) as they will go. Refer to Detail 22 and cut off the lugs of @ 2-lug terminal strip as shown, BD 46 ockwasuer caPaciToR MOUNTING WAFERS Q 320318" screw capacitor MOUNTING WAFERS Detail 228 Q 632 asi () Refer to Detail 228 and, on the top of the chassis, 4 screw install two capacitor mounting wafers at each of holes 3, C4, C5, and C6. Use 6-32 x 3/8” screws. Turn the screws into the nylon insulators. Detail 22D o % Hm 1 mom 2 3 4 5 ‘ ogee tee Pal eon eres ewe eee ete ov tars SCSo () Refer to Detail 22D and install two capacitor ‘mounting wafers at C7. Mount the 2-ug terminal strip, tunder the chassis at EP. Use 6-32 x 3/8” screws, #6 lockwashers, and 6-32 nuts, (_) Install two capacitor mounting wafers at hole C8, Use 6-32 x 3/8” screws, #6 lockwashers, and 6-32 nuts. CAUTION: The filter capacitors in the high voltage circuit will be wired next. To avoid difficulty later, be sure to review each step a second time to make sure there are no wiring errors. { ) C3, C4, C5, C6, C7, CB: Refer to Detail 22E and install six 125 pF electrolytic capacitors in the six mounting locations. Be sure to position the positive lug of each capacitor as shown in Detail 22F, Note carefully for each capacitor which lugs are twisted to hold the capacitor to the wafer. Use pliers to twist va TURN Detail 22E () R3, R4, R6, RG, R7, RB: Refer to Detail 22F and install a 100 k®, 2-watt (brown-black-yellow) resistor on the bottom of each filter capacitor, Solder the six Page 57 connections marked “solder” in the Detall. Bend the longer lead as closely as possible to the body of the resistor to provide as much clearance as possible from. the negative capacitor lug. Position the resistor in the square wafer opening (_) Prepare the following lengths of large blue wire: 14/2" 3" 3a" 14/2" 14/2" Connect these large blue wires between capacitors as follows () 1-1/2" from €3 (S-1) to C4 ($2). () 3-1/4" from C4 (S-1) to C5 (S-2). () 1-1/2" from C5 (S-1) to C6 (NS). () 3" from €6 (S-1) to C7 (S-2). () 1-1/2" from C7 (S-1) to C8 (S-2). Detail 22Fret SEs ‘ ( Refer to Pict ( Detail 226 ) R11: Refer to Detail 22G and connect a 680 2 (blue-gray-brown-gold) resistor from terminal strip EP, the lower hole of lug 1 (NS), to mounting lug of CB (S-1), Provide clearance as shown between this resistor and the positive lug of C8. }. Connect the white-black wire coming from grommet DC to terminal strip EP, the lower hole of lug 1 (S-2}. } RQ: Cut one lead of a 1 2, S-watt, 1% resistor to 1-1/4" Place a 1" length of smelt black sleeving on this lead and connect the lead to C8 lug ER (NS). Connect the other lead to terminal strip EP, the lower hole of lug 2 (S-1). ( Propare a 15” length of white-black wire and solder a female connector to one end. From the top of the chassis, push the other end of the wire down through ‘grommet DC and connect it to C8 lug ER (S-2). Start_ with the step for mounting the six filter capacitors and Detail 22F, and check every connection for accuracy and for compliance with the solder instructions. Check the position of the positive lug of each capacitor. Connect the red wire coming from grommet DC to terminal strip DE lug 1 (NS). Remove another 1/4” of insulation from the White-yellow wire coming from grommet DC. Connect, this wire to socket EA, through lug 9 (S-2) to lug 8 (s4). Prepare a 26” white-red wire and solder a female connector to one end. From the top of the chassis, push the free end down through grommet DC, ‘At the free end of the white-red wire, remove an. additional 1/4” of insulation. Connect this end of the wire to socket EA, through lug 4 (S-2) to lug 3 (NS). Prepare a 17” black wire. Connect one end of this wire to socket EA, lug 3 (S-2). Push the other end of this wire up through grommet EC. ASSEMBLED CHASSIS 23 for the following steps. } Place the power supply chassis alongside the RF enclosure as shown. As you position the power supply chassis, start the two brown wires in the black sleeving and the four wires with the female connectors (red, yellow, violet, and white-xed) through grommet BN. into the RF enclosure. Check for any wires which might be pinched between the chassis and enclosure, ‘Then fasten the two assemblies together with 6-32 x 3/8" screws, #6 lockwashers, and 6-32 nuts at holes BH, BK, and BP, At hole BR, use 6-32 x 3/8” hardware and a #8 long lug. % % 1 omens 2 a 4 5 6 7 aie re L ee n Jog 1 eee eee i Jj i aGa guesrHrire Page 59 6-32 NUT #6 LOCKWASHER #8.LONG LUG 6.39 x 3/gn S c Nas uf PICTORIAL 22 varoata PICTORIAL 23Page 60 LE" BLK-RED MEASURE FROM HERE Detail 24A 12" RED-YEL [<—3¢ oeov ome orange 4" BLK “ BLK-YEL 4" BLK-GRN 9" BLU 4-1/2" BLU 5-1/2" GRN 5-1/2" GRN Refer to Pictorial 24 (fold-out from this page) for the SCREW ( ) 3/4" 0.0. & 4 $ FLAT WASHER ® cocewasner % 10-32 NUT ( ) © © Detail 248 10-32 x 1/2" following steps. Refer to Detail 24A and cut the leads of the power transformer to the following lengths. Measure all leads from where they exit from the end bells. After cutting the leads, remove 1/4” of insulation from the end of each lead. If the stranded leads are not solder coated, twist the fine strands together and melt a minimum amount of solder on each to prevent the strands from “straying” and possibly causing a short circuit. Lead Cut Color To: Red 9” Red/yellow 12” Black 4" Black/yellow 4” Black/green 4" Black/red 4” One blue 9” Other blue 4-1/2" Both green 5-1/2" Ti: Refer to Detail 24B and mount the power transformer at holes DP, DR, DS, and DU. At each hole, use a 10-32 x 1/2" screw, a 3/4” O.D. flat washer, a #10 lockwasher, and a 10-32 nut. As you lower the transformer into place, insert both green T" CLEAR SLEEVING 10-32 x 1/2" SCREW FEMALE CONNECTOR RED RED-YEL " BLU PICTORIAL 24leads and the 4-1/2” blue lead down through grommet DT. NOTE: yw Insertion of the screws into holes DP and refer to the inset drawing on the Pictorial and use the 7” length of clear sleeving ‘a8 an aid for placing the screws. Save the sleeving for use later. Check to make sure there are no transformer leads or ‘other wires pinched under the transformer. Solder a female connector to the end of the red transformer lead. Solder a female connector to the end of the 9” blue transformer lead. Bring the red/yellow lead around the end of the filter capacitors and push it down through grommet DC. 6-32 53/8" screw #6 souner Lus Detail 24¢ Remove and discard the screw from lug 2 of the 6-screw terminal strip. Refer to Detail 24C and replace this screw with a #6 solder tug and a 6-32 x 3/8” screw. Turn the screw only halfway Point the solder lug toward the transformer and solder the #6 solder lug to the terminal strip metal on the top of the terminal strip insulator. Try to keep the solder away from the scrow threads (the screw is resent during the soldering to maintain the correct alignment of the solder lug with the screw threads). % 1 mente 2 a huetemere ly 'A. MECHANICALLY SECURE CONNECTION. Page 61 WRAP AND MAKE BLK RED Detail 24D Refer to Detail 24D and connect transformer primary leads to the solder lugs of the 6-screw terminal strip as follows. Make sure each connection is mechanically secure before you solder it. To make a mechanically secure connection, insert the wire through or wrap it around the lug or terminal, or both, before soldering. See the inset drawing. {} Remove an additional 1/2” of insulation from the black/red lead. Push this lead through lug 5 (S-3) to. tug 6 (S-1). Connect the black/yellow lead to lug 4 (S-2). {) Connect the black/green lead to lug 3 (S-1). Connect the black lead to the solder lug which was ‘added to sorew 2 (5-1) () Refer to Pictorial 24 and connect the brown wire coming from the solder lug under spacer DX to the solder lug on the transformer core bolt (S-1)..Page 63 = = cae - i REMOVE THE OUTER INSULATION PUSH BACK THE SHIELD. THEN MAKE AN OPENING IN THE SHIELD AND BEND OVER AS SHOWN, PICK OUT THE INNER LEAD, Se be REMOVE THE INNER INSULATION AND STRETCH OUT THE SHIELD. APPLY A SMALL AMOUNT OF SOLDER TO THE END OF THE SHIELD AND INNER LEAD, USE ONLY ENOUGH HEAT FOR THE SOLDER TO FLOW Twist into POINT Detail 25A Refer to Pictorial 2 for the following steps. () At one end of the coaxial cable, connect the inner conductor to relay lug 4 (S-1). The shield wires will be (\) Prepare a 16” white wire. Connect one end of this connected later. wire to relay lug 12 (S-4). Position this wire down against the chassis and push the other end through ( ) Push the other end of the coaxial cable through ‘grommet BF into the RF enclosure. grommet BF into the RF enclosure. Bend the cable down and secure it by wrapping lug TE around the () Route the black wire (coming from grommet EC) body of the cable. Then connect the inner conductor under the relay, along the white wire, and through 10 loading capacitor C15 at solder lug BD. Use the lug grommet BF as in the previous step. to which the RF choke was soldered (S-1), Connect the shield wires to the solder lug at BC ($-2).. () Refer to Detail 254 and prepare an 18” coaxial cable. ou He % 1 omen 2 3 feftae ieee)Page 64 Bars = GROUND LUG bo ° Ee. CL] ° WARNING . . ° e 2 e PICTORIAL 26 om oe ES sore NS Q@ scent “O Detail 264 Refer to Pictorial 26 for the following steps. () J1, 42, J3: Refer to Detail 26 and install phono jacks at J1, J2, and J3 on the rear panel. Use 6-32 x 3/8” hardware at each mounting hole. Position the ground ug as shown, ou HK 1 cmemesy 2 3 fossa tse) é ( Lockyasnen oe Detail 268 ) J&: Refer to Detail 268 and install a coaxial connector at J4 on the rear panel. Use 4-40 x 5/16” hardware.10-24 WINGNUT 0.0 3 WASHERS 20-24 WUT 410 LOCKWASHER a SCREW Detail 26¢ (). Refer to Detail 26C and install 2 10-24 x 3/4” screw, a #10 lockwasher, a 10-24 nut, two 3/4” O.D, flat washers, and @ 10-24 wingnut at GS on the rear panel, 6324318 SCREW Detail 26D () ZD1: Refer to Detail 26D and install a 1N2B06A zener diode (#56-609) on the rear panel, Use 6-32 x 3/8" screws at GP and GQ. () Refer to Detail 26E and install the fuseholder at GL fon the rear panel using the rubber gasket and the hardware supplied with the holder. () Fi: Install the 3/4 ampere, slow-blow fuse in the fuseholder. Page 65 FusewoLoeR 0} RUBBER 4h GASKET oO Detail 26E () Prepare a 2-3/4” yellow wire. Connect one end of this wire to the solder lug on the side of the fuseholder (4). () Remove an additional 1” of insulation from the free end of the yellow wire. { ) Connect the free end of this yellow wire to zener diode ZD1. Wrap the yellow wire around either diode pin (S-2) and then connect the wire to the remai pin (S-1). WARNING: ‘The thermal compound used in the following step (and later when mounting the amplifier tube) can be injurious to both your eyes and your clothes. It should be handled with utmost care. KEEP THE COMPOUND AWAY FROM YOUR EYES. Wash your hands immediately after using the compound, ‘Should you get any in your eyes, wash them out with water at once and get to a doctor as soon as possible, KEEP THE COMPOUND OFF YOUR CLOTHES. If you get the compound on your clothes it may leave a permanent white stain,3 FINS HEAT SINK DeINs Z é REAR PANEL 4 Ss. Cee @y .0 PICTORIAL 27 Detail 27A aad Lee screw Refer to Pictorial 27 for the following steps. () Refer to Detail 27A and open one of the thermal compound pods by cutting across the corner and into Detail 27B ‘the pod just enough to make a small opening. Use diagonal cutters or scissors. () TCI: Refer to Detail 278 and mount the thermal (.) Refer to Detail 278 and squeeze out an amount of circuit breaker on the heat sink at the location shown. ‘thermal compound equal to a medium sized pea; then Use 4-40 x 1/4” screws. If you get any of the thermal smear it evenly over the back of the thermal circuit compound on your fingers while mounting the breaker. WASH YOUR HANDS. ‘thermal circuit breaker, wash your hands again,Poge 67 6-32.03/0" screw Detail 27E THERMAL comPouND Refer to Detail 27E for the following two steps. Detail 27C (Mount cover brackets at GA and GH. Use 6:32 x 3/4” (} Refer to Detail 27C and make lines of thermal hardware. Position the long side as shown. Compound on the face of the heat sink. DO NOT use more than two pods. KEEP the compound at least { ) Push a 6:32 Speed Nut onto each bracket so the holes 1/2" from the holes in the heat sink. in the nuts and brackets are aligned. The curved lip of each nut must be on the under side of the bracket. ()- Tighten all heat sink hardware, soar” sueer a 3 FINS Detail 27D (1. Refer to Detail 27D and mount the heat sink and the rear panel assembly to the back of the RF enclosure and the power supply chassis. Use 6-32 x 3/4" hardware at holes GB, GC, GJ, and GK. Use #6 x 1/2” SINS sheet metal screws at holes GN, GR, and GY. DO NOT tighten the hardware yet. 632 3/8" SCREWTor View fat T Fo T CAPAEITOR LEAD \ ohio PICTORIAL 28 Sie Refer to Pictorial 28 for the following steps. 6, aa () Remove the type 8873 tube from its package. HANDLE THE TUBE CAREFULLY-itis expensive. me Refer to Detail 28 for the following two steps. () Bend 7/16” of each end of the two silver-plated grid straps (#212-45) as shown, () Form the silver-plated grid straps around the grid ring Dose asi of the tube. Use 2:56 x 3/8” hardware. Place the i sera protruding tabs so they are positioned as shown in Pictorial 28 and tighten the hardware. Refer to Detail 288 for the next two steps. bose nur () Mount a #6 solder lug on the tube plate clamp. Use a 6-32 x 1/4" screw. Position the solder lug as shown. () Start a 3.48 x 7/16” brass screw into the tube plate clamp, Place the plate clamp on the tube with the opening in the clamp toward the flat on the tube. Then tighten the screw. FUT Detail 28Aazar Page 69 BERYLLIUM OXIDE CERAMIC BLOCK CAUTION: Do not heat it over 1,000°C (unit operation will not exceed 400°C). Dust and fumes of Beryllium Oxide are DEADLY POISONOUS and should not be inhaled or brought into Wash hands after handling. Contact with the skin or eyes, If itis dropped, remove any chips and dust with a wet towel, Do not perform any dust-producing operations (drilling, which should be discarded in a sealed plastic bag — do not chipping, crushing, sawing, or filing) on the block. ‘sweep of vacuum. SCREW XN ge 6 soupen ruse miate 2 MI" THICK THERMAL " comPouno pa SERED 5-43 x 1/16" eas sone ar Detail 294, GE in the rear panel. Rotate the block back and forth slightly to insure adequate contact between the beryllium block, the compound, and the heat sink. {) Coat the flat side of the tube with @ 1/16” thick coating of thermal compound. Refer to Pictorial 29 (fold-out from Page 71) for the following steps. () Vit Insert the tube into its socket. As you seat the tube, wiggle it against the beryllium oxide block so the () Refer to Detail 29 and carefully remove the thermal compound will form a solid bond with the beryllium oxide block from its packaging. Apply a beryllium oxide block. 1/16" thick costing of thermal compound to one side. Then place this side against the heat sink at opening ( ) WASH YOUR HANDS, wow % 1 mere 2 3 5 ‘ 7 seqebemsr | J Loyal og i Dot pot ty rt ptt ttPage 70 NOTES: Be very careful when forming the lead and mounting each feedthrough capacitor in the following steps, as. the ceramic body can be broken, In the two following steps, turn the nuts finger tight only, as the position of the two capacitors will be adjusted later. ReMave AND SAVE NUT Detail 298 ) Refer to Detail 298 and, at the end opposite the threads, carefully straighten and bend the lead of each feedthrough capacitor as shown. ) Cut off the lead at the threaded end of each capacitor. } Remove the nut from each feedthrough capacitor. ) C23: Refer to Detail 29C and insert one of the feedthrough capacitors into hole C23 from the top of the rear of the chassis, as shown. Secure the capacitor fon the bottom of the chassis with the nut removed in the preceding step. ) C31: Similarly, mount the other feedthrough capacitor in hole C31, except that the bent lead should point toward the front of the chassis. Refer to Detail 290 for the next five steps. ) From the back of the heat sink, insert 8-32 x 3” screws into holes GF and GG. Start these screws into the two tapped holes of the tube mounting bracket. ) SES Detail 29C Insert the small tip of the white insulator (#75-701) into the center hole of the tube mounting bracket and the other end of the insulator against the tube body. Then tighten the two long screws until the tube ‘mounting bracket just starts to bow. Solder one tab on the grid strap to the lead of capacitor C23. Solder the other tab on the grid strap to the lead of capacitor C31. After the solder has cooled, tighten the nuts on the ‘two feedthrough capacitors. Refer to Detail 29 and prepare a ferrite bead assembly: Bend down 1/4” of the end of a 3" bare wire. ‘Thread two ferrite beads onto the wire, Bend a 1/8" “dog leg” to retain the beads at one end of the wire,Ge QurmarHxrite Page 71 TUBE MOUNTING BRACKET ° rx YE FERRITE BEADS Pale Detail 29E () Push the straight end of the ferrite bead assembly through the solder lug on the tube plate clamp (NS). Bend the solder lug up as necessary. Drop the other (bent} end of the wire into the solder lug on the upper end of the RF choke CM (NS). Use the hole nearest the solder lug screw. o + wy % 1 (INCHES) 2 3 Detail 29D Connect a 3-1/2” bare wire from the solder lug at BE (S-1} to the solder lug on the tube plate clamp (5-2). Connect the white wire coming from grommet BF of the RF enclosure to thermal circuit breaker GD lug 2 (S-1). Connect the black wire coming from grommet BF of the RF enclosure to thermal circuit breaker GD lug 1 (S-1). Prepare a 14” large blue wire. From the bottom of the chassis, push this blue wire up through grommet CL and connect it to RF choke CM at the bottom lug (S-2). 4 5 6 7 1/6, 3/8 |) 5/8, 7/8 Oo 8 414 (cM) 2 3 4 5 8 7 a 10 44 12 13 14 15 16 17 UBE PLATE FERRITE BEAD C) CLAMP ‘sseueny Detail 29F FERRITE BEAD 0 ASSEMBLY c LaF cuoxe } CHOKE (es B “WS 2 PICTORIAL 2922-1/2" WHT-YEL YEL’ , ter ve LL XR 16" | i iM 3 @D bain & 5 ft CABLE FEMALE 18" LARGE CONNECTOR 23-8 BLU PICTORIAL 30 Page 72 Refer to Pictorial 30 (fold-out from this page) for the following steps. () Prepare a 7” yellow wire. Connect one end of the wire to the solder lug on the end of the fuseholder (S-1). Push the other end of the wire through grommet BG. CAUTION: To avoid damage to the relay solder lugs, form and fit the bare wires in the following steps before you solder either end. { ) Refer to Detail 30A, form a 1-1/2" bare wire to connect coaxial fitting J4 (S-1) to relay lug 7 (S-2). At the relay, form the wire so it touches the relay lug and the resistor lead. 7) t ea tL Me 1-1/2" BARE WIRE Mey 5/3" Detail 30A Detail 30B ) Refer to Detail 30B and form a 2-1/4” bare wire to connect relay lug 10 (S-1) to phono socket J3 at its center terminal (S-1). ~ Connect the twisted shield wires of the coaxial cable to phono socket J3 at its ground lug (S-1). Cut off any excess shield braid. Make sure the shield wires clear the center terminal of the phono socket by at least 1/4", Connect the yellow wire coming from the meter switch to phono socket J2 at its center terminal (S-1). ~ Prepare a 22-1/2” white-yellow wire, Connect one end of this wire to phono socket J1 at its center terminal (S-1). Push the other end of the wire down through grommet EC, Detail 30C () Refer to Detail 30C and prepare a 16” length of coaxial cable. { ) At one end of the cable, connect the inner conductor to relay lug 6 (S-1). Push the shield wires through a 1/2” length of small clear sleeving and connect the wires to the solder lug between the spacer and the relay (S-1). Push the other end of the cable down through grommet EC. ( ) Prepare an 18” targe blue wire and solder a female connector on one end. Position this end of the wire over the long !ug at DE. Push 5” of the other end of this wire down through grommet DC, Detail 30D () Refer to Detail 30D and bend the long Jug at DE so it encircles ail the wires which pass it, including the brown twisted pair. CABLE TIE Detail 30E (|) Refer to Detail 30E and place a cable tie around all the wires at DN. Pull the tie up snugly and cut off all but 1/4” of the excess tie length.GegruearHxKit: Refer to Pictorial 31 (fold-out from this page) for the following steps. ( } Prepare two 7” small brown (tinned) wires. Form a twisted pair. (_ } Connect the wires at one end of the twisted pair to socket EA, lugs 1 (S-1) and 6 (S-1). ( ) Push the other end of the twisted pair through grommet EN and connect it to terminal strip TE, lugs 1 (NS) and 2 (NS). ( ) Connect the blue wire coming from grommet DT to the solder lug at DZ (S-1). ( ) Form a twisted pair from the two green wires coming from grommet DT. Push the twisted pair through grommet EN. { ) Connect one wire of the green twisted pair to terminal strip TE lug 2 (S-3), and connect the other wire to lug 1 (S-3), (_ ) Push the white-yellow wire coming from grommet EC through grommet EN. Position this wire in the chassis corners and connect it to terminal strip TA lug 6 (S-3). {_) Push the white wire coming from grommet EC through grommet EN and connect it to terminal strip TC Jug 2 (NS). ( } Push the violet wire coming from grommet DC through grommet EN and connect it to terminal strip TC lug 2 (S-2). ( ) Push the white-blue wire coming from grommet DC through grommet EN and connect it to terminal strip TC lug 1 (S-2). ( ) Twist the long lug at BR around the violet, white-black, and white-blue wires to hold them in place. Refer to Pictorial 32 for the following steps. (_} Push the coaxial cable coming from grommet EC through grommet EN, between terminal strip TC and the chassis lip, and under the ends of the two terminal boards. Connect the cable to terminal strip TA: the shield wires to the lower hole of lug 3 (S-1) and the inner conductor to the lower hole of lug 1 (S-1). oO % %% A 1 (INCHES) 2 3 Page 73 (_ ) Connect the yellow wire coming from grommet BG to terminal strip TD lug 4 (S-3). (_ ) Push the large blue wire coming from grommet CL through grommet EN and connect it to capacitor C3 lug ES (NS). (_ } Connect the large blue wire coming from grommet DC to capacitor C3 lug ES (NS). Pull any excess wire back through grommet DC. ( ) Connect the red-yellow wire coming from grommet DC to capacitor C6 lug ET (S-3). ( ) R15: Connect a 100 kQ (brown-black-yellow) resistor to terminal strip DE between lugs 1 (S-1) and 2 (NS). ( } Refer to Detail 32A and prepare a 3-megohm resistance assembly from three 1 megohm, 2-watt (brown-black-green) resistors and a 3” length of large clear sleeving. (t) CUT LEADS OF 1MQ (BROWN-BLACK-GREEN) . 2-WATT RESISTOR AS SHOWN, DO NOT CUT 3/8" 3/8" DO NOT CUT AN TR f @) FORM HOOKS IN THE 3/8" LEADS. —_b « C. yy > = \ Sw ; No SoS : SRA ww Wer, WS nN WW \ x Rag SY \ TAN WX Ly S Sw AQ eS NY SP. we | a . Ws AAS NS Rie TOP WINDOW BRACKET geo” NUT “~~ #4 LOCKWASHER BOTTOM WINDOW BRACKET RED WINDOW Detail 34BCeeececece cececeee, cocetees, Teese fi PICTORIAL 37 Page 80 METER SWITCH SHORTER PICTORIAL 35 Refer to Pictorial 35 for the following steps. ( ) Carefully inspect the back of the meter. If there is a wire between the positive and negative terminals, remove and discard it. ( ) Bend the center (negative) terminal of the meter so it points straight back. ( ) ©18: Connect a .001 pF disc capacitor between the two meter terminals (NS). ( ) Connect the black wire coming from the 1-wafer switch to the negative (unmarked) meter terminal (S-2). ( ) Connect the white-red wire coming from the 1-wafer switch to the positive (marked ‘’+’’) meter terminal {S-2). ( } Connect the brown twisted pair to the pilot lamp socket, one wire to lug 1 (S-1) and the other wire to tug 2 (S-1). ( } Push the connectors on wires coming from grommet BN onto pins of the lamp indicator circuit board as follows: Yellow onto pin 4. Violet onto pin 2. White-red onto pin 3. Red onto pin 1. o KY % % 1 uncnesy 2 3 { } Place a cable tie around the four colored wires in the preceding step, about halfway between the circuit board and the grommet. Pull the tie up snugly and cut off all but 1/4” of the excess tie length. { ) Refer to Pictorial 36 for the following steps. tNTERLOCK SWITCH) Detail 364 ie E > { ) Refer to Detai! 36A and identify the interlock switch lug marked NC on one side of the switch body. Grasp this lug with pliers and bend it back and forth until it breaks off. Break off this lug on both interlock switches, ( ) SW5: Refer to Detail 36B and install an interlock switch at GT and GU on the right side of the RF enclosure. Be sure the switch button is on the underside of the switch, Use 6-32 x 1" hardware. Note the number of nuts used. { ) SW4: Similarly, install the other interlock switch at GW and GZ. The switch button should be on the upper side of the switch, { ) Prepare large brown (stranded) wires as follows: 3-1/4" 5" 4 5 6 7 78, 9/8) 5/8, 778 O 8 + (cm 2 3 4 5 6 7 8 10 ” 12 13 14 15, 16 7Page 81 FRONT PICTORIAL 36 (.) Refer to Detail 36C and install push-on connectors on each end of the 3-1/4” brown wire. #6 LocKwasHeR | 6-32 aur 1 (_)- Install a push-on connector on one end of the 5” wire. (.) Install @ push-on connector on the end of the longer brown wire coming from the biack sleeving. (Push this connector onto the rear lug of SW5. (_) Push one connector on the 3-1/2" wire onto the front lug of SW4 and the other connector onto the front lug of SW5. (.) Push the connector on the 5” wire onto the rear lug of sw, NOTE: In the following two steps, push each wire through the switch lug and wrap it around the lug to make a ‘mechanically secure connection. Z () Connect the shorter brown wire coming from the sens over Duck seve to SWI at te a marked ne” IS RA Ze 1) Connest the brown wire coming from the reer tug of phan, ond we oberia awn (ea. Detail 36C